Rexroth

Oil Cleanliness Booklet

Oil Cleanliness Booklet | Introduction

Introduction

Oil is the central component of any hydraulic system.

If a system fails, contamination is one of the major reasons.
This booklet explains the basics of contamination control
and serves as a reference and information tool.

Content | Oil Cleanliness Booklet

04 Need for Hydraulic Filtration

05 Sources of Problems with Fluid Systems
06 Classical Oil Analysis
07 MPC 4614 Mobile Particle Counter
08 Contamination Types, Origin, Examples
12 Damage Caused By Contamination
13 The Objective
14 Filtration Grade Particle Sizes
16 Achievable Oil Cleanliness in Accordance with ISO 4406
17 Overview of the Key Filter Properties
18 Fitting Tolerance of Hydraulic Components
19 Recommended Oil cleanliness level
20 Oil Cleanliness Codes in Accordance with ISO 4406
32 Fluid and Product Service
33 Fluidmanagement Products
41 Notes

Oil Cleanliness Booklet | Need

Need for
Hydraulic Filtration
Inspecting contamination in
hydraulic systems is a major
aspect when designing a lter
concept.

Sources of Problems | Oil Cleanliness Booklet

Sources of Problems
in Fluid Systems
More than of all problems
can be traced back to contaminated oil. Monitoring oil cleanliness is therefore the most
important factor in preventing
system failures.

Monitoring hardware only

detects around 20 % of all
unplanned downtimes.

Components
20 %

80 %
Fluid

Oil Cleanliness Booklet | Oil Analysis

Oil Analysis

Types of inspection for oil cleanliness

f Ofine examination of oil
samples in the laboratory
f Microscopic particle count in
accordance with ISO 4407

f Gravimetric test in
accordance with ISO 4405
f Microscopic determination of
the type of contamination

Vacuum ltration device:

e Oil sample

e Test membrane
c Test membrane, 1,2 m

e Vacuum

e Filtrate
c Microscopic image, 100 x

Particle Counter | Oil Cleanliness Booklet

Mobile Particle Counter for Conducting Online

Measurements of the Oil Cleanliness Class
f Light extinction principle
f Laser sensor
f Robust and reliable device
with all basic functions
f Integrated battery pack and
memory
f Oil cleanliness classes in
accordance with ISO 4406
4 m(c), 6 m(c), 14 m(c)
f Comprehensive range of
accessories, e.g. printer, tank
pump, external memory card
f Very easy to use

c MPC 4614

c Tank pump

c Printer

Oil Cleanliness Booklet | Types of Contamination

Types of Contamination

1. Solid particles
(abrasion and dirt)

Consequences:
f Initial damage through
scoring
f Impact on control and
regulation properties
f Component wear
f Component failure
f Reduction in machine
availability
Measures: Filtration

Types of Contamination | Oil Cleanliness Booklet

2. Liquid contamination
(usually water, free and in
solution)

3. Gaseous contamination
(air)

Consequences:
f Corrosion, wear
f Impairment of viscosity
f Chem. reaction with the uid
f Impact on lubricating
properties
f Ageing (oxidation) of oil
f Poor lterability
f Reduction in lter service
intervals
f Reduction in machine
availability

Consequences:
f Foam formation in the oil
f Inaccurate valve response
f Loss of energy
f Pump damage
f Chem. reaction with the uid
f Oxidation
f Reduction in machine
availability

Measures:
f Breather lters with AS lter
material
f Water absorbing lter
elements (free)
f Vacuum dehydrator (water in
solution)

Measures:
f Bleed system
f Seal pumps
f Use a vacuum dehydrator

10

Oil Cleanliness Booklet | Origin

Sources
of Contamination
1. Built-in contamination

2. External contamination

f Foundry sand, dust

f Manufacturing residue:
- Welding residue
- Metal swarf
- Blasting material,
lacquer/paint particles
- Preservation material
f Residue from cleaning agents
(textile bers)

f Dirt from the ambient air,

introduced via
- Plunger rods
- Labyrinth seals
- Aeration
f Contamination caused by
adding oil

3. Self-generated
contamination
f Metallic wear caused by
abrasion and erosion
f Seal abrasion
f Chemical corrosion
f Oil ageing products
f Oxidation residue
f Oil-insoluble substances
caused by mixing oil

Residual Dirt | Oil Cleanliness Booklet

Examples
of residual dirt
Built-in contamination
Residue from a return line lter
(mobile hydraulic systems)
f
f
f
f

Welding residue
Metal swarf
Paint residue
Resin

Self-generated
contamination (wear)
Residue from a high-pressure
lter in a hydraulic system within
a stainless steel forging press
f Coarse brass and steel
abrasion particles
f Severe sliding wear (grooves
and stress marks)

11

12

Oil Cleanliness Booklet | Damage

Damage Caused
By Contamination
Material removal (erosion)
caused by a high ow rate
along edges combined with a
high number of ingressed dirt
particles with high speed in the
ow.

Grooving (abrasion)
caused by hard, abrasive particles that are roughly the same
size as the clearance of the
components.
Consequence: Reduction in
performance due to leaking oil.

The Objective | Oil Cleanliness Booklet

The Approach

Prevent with Rexroth lter technology.

f Optimum oil cleanliness
f Reliable component
protection

f High degree of oil

contamination
f ISO 22/20/18

f Major contribution towards

machine availability
f High degree of customer
satisfaction

f Achievable oil cleanliness

using ne lter elements
f ISO 12/10/8

13

14

Oil Cleanliness Booklet | Filtration Grade Particle Sizes

Filtration Grade
Particle Sizes

Bacteria 0,3 20 m

0 mm

Viruses 0,003 0,05 m

Field of application
0,05

0,1

0,2

c Tobacco smoke 0,01 1 m

0,5

c Blood cells 0,5 1,5 m

Filtration Grade Particle Sizes | Oil Cleanliness Booklet

Human hair ~ 70 m

1 mm

Pollen ~ 20 m

15

Rexroth Filter
10

20

30

c Visibility limit = 40 m

50

100

200

500

1000 m

Particle sizes are measured in

units called micrometers.
A micrometer is one millionth
of a meter.
The visibility limit of the human
eye is approx. 40 m. This means
that particles that are the most
hazardous to a hydraulic system
cannot be detected with the
naked eye.

16

Oil Cleanliness Booklet | Achievable Oil Cleanliness

Achievable Oil Cleanliness

in Accordance with ISO 4406
HydroClean XL lter material
H20XL

19/16/12 - 22/17/14

H10XL

17/14/10 - 21/16/13

H6XL

H3XL

H1XL

15/12/10 - 19/14/11

13/10/8 - 17/13/10

10/6/4 - 14/8/6

Key Filter Properties | Oil Cleanliness Booklet

17

Overview of the most important lter characteristics

Filtration grade
f Nominal (from manufacturer)
f Absolute in accordance
with ISO 16889
f Mesh width for wire fabric

Dirt absorption capacity

f In accordance with ISO 16889
f ISOMTD test dust

Differential pressure
f In accordance with ISO 3968
f In relation to 30 cSt/25 m

All three properties are mutually

interdependent. Rexroth lter
elements are characterized
by an optimum ratio for these
properties, ensuring the best
possible ltering action with
maximum dirt absorption and
minimum p.

18

Oil Cleanliness Booklet | Fitting Tolerance

Fitting Tolerance of
Hydraulic Components
Gear pump
Gear pump,
Side plate
Gear housing

0,5 - 5 m
0,5 - 5 m

Vane pump
Vane tip
Vane surfaces

0,5 - 5 m
5 - 13 m

Piston pump
Piston bore
Valve plate cylinder

5 - 40 m
1,5 - 10 m

Servo valve
Control piston
Bafe plate

18 - 63 m
2,5 - 8 m

Control valve
Control piston
Cone valve

2,5 - 23 m
13 - 40 m

Extract from CETOP RP 92H

Examinations show that even

particles with sizes that are
1/ x the clearance width can
3
lead to the clearance becoming
blocked. The ltration grade of
the system lters should therefore be selected in such a way
as to ensure the absolute
ltration grade is smaller than
or equal to 1/3 of the smallest
clearance width in the system.

Filtration grade 1/3 x smallest clearance

Recommended Oil cleanliness | Oil Cleanliness Booklet

Recommended
Oil cleanliness level
Application

Oil cleanliness
required in
accordance
with ISO 4406

Recommended
lter material/
ltration grade

Systems with extremely high

dirt sensitivity and very high
availability requirements

16/12/9

H1XL / 1 m

Systems with high dirt

sensitivity and high availability requirements, such as
servo valve technology

18/13/10

H3XL / 3 m

Systems with proportional

valves and pressures > 160 bar

19/14/11

H6XL / 6 m

Vane pumps, piston pumps,

piston engines

18/16/13

H10XL / 10 m

Modern industrial hydraulic

systems, directional valves,
pressure valves

20/16/13

H10XL / 10 m

Industrial hydraulic systems

with large tolerances and low
dirt sensitivity

21/17/14

H20XL / 20 m

19

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Oil Cleanliness Booklet | Oil Cleanliness Codes

Oil Cleanliness Codes in

Accordance with ISO 4406 and
Examples of Contamination
Number of particles
(per 100 ml)
from

ISOCode

Classication of all particles

4 m(c), 6 m(c) and
14 m(c)

to
Example from ISO 18/16/11:
190.000 particles 4 m(c)/100 ml
58.600 particles 6 m(c)/100 ml
1.525 particles 14 m(c)/100 ml

1.000.000

2.000.000

21

500.000

1.000.000

20

250.000

500.000

19

130.000

250.000

18

64.000

130.000

17

ISO 4406 counts particles accumulatively,

32.000

64.000

16

i.e. all particles that are larger than or equal

16.000

32.000

15

to 4 m. In contradiction to this, NAS 1638

8.000

16.000

14

4.000

8.000

13

2.000

4.000

12

NAS 1638 became INVALID on 05/30/2001!

1.000

2.000

11

The replacement standard SAE AS 4059

500

1.000

10

is a national standard intended for the US

250

500

aviation industry only. It is therefore no

130

250

longer permitted to specify contamination

64

130

32

64

16

32

counts the particles in differential size

classes, i.e. all particles within the range of
5 15 m, 15 25 m, etc.

classes in accordance with NAS. Specifying

contamination in accordance with ISO 4406
on the other hand is considered to be
state-of-the-art.

Oil Cleanliness Codes | Oil Cleanliness Booklet

ISO 10/7/5

(NAS 1638: class 1)

Particle size
4 m(c)

6 m(c)

14 m(c)

64 to 130

16 to 32

Particle count
500 to 1.000

21

22

Oil Cleanliness Booklet | Oil Cleanliness Classes

ISO 12/11/6

(NAS 1638: class 2)

Particle size
4 m(c)

6 m(c)

14 m(c)

1.000 to 2.000

32 to 64

Particle count
2.000 to 4.000

Oil Cleanliness Classes | Oil Cleanliness Booklet

ISO 14/13/9

(NAS 1638: class 3)

Particle size
4 m(c)

6 m(c)

14 m(c)

4.000 to 8.000

250 to 500

Particle count
8.000 to 16.000

23

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Oil Cleanliness Booklet | Oil Cleanliness Classes

ISO 16/14/10

(NAS 1638: class 5)

Particle size
4 m(c)

6 m(c)

14 m(c)

8.000 to 16.000

500 to 1.000

Particle count
32.000 to 64.000

Oil Cleanliness Classes | Oil Cleanliness Booklet

ISO 17/15/13

(NAS 1638: class 6)

Particle size
4 m(c)

6 m(c)

14 m(c)

16.000 to 32.000

4.000 to 8.000

Particle count
64.000 to 130.000

25

26

Oil Cleanliness Booklet | Oil Cleanliness Classes

ISO 18/16/13

(NAS 1638: class 7)

Particle size
4 m(c)

6 m(c)

14 m(c)

32.000 to 64.000

4.000 to 8.000

Particle count
130.000 to 250.000

Oil Cleanliness Classes | Oil Cleanliness Booklet

ISO 19/17/14

(NAS 1638: class 8)

Particle size
4 m(c)

6 m(c)

14 m(c)

64.000 to 130.000

8.000 to 16.000

Particle count
250.000 to 500.000

27

28

Oil Cleanliness Booklet | Oil Cleanliness Classes

ISO 22/19/17

(NAS 1638: class 10)

Particle size
4 m(c)

6 m(c)

14 m(c)

250.000 to 500.000

64.000 to 130.000

Particle count
2.000.000 to 4.000.000

Examples of Contamination | Oil Cleanliness Booklet

Fatigue wear, 500 x

Sliding wear, 500 x

Cutting wear, 100 x

29

30

Oil Cleanliness Booklet | Examples of Contamination

Cutting wear, 500 x

Dark, shiny metal, 500 x

Copper particles, 500 x

Examples of Contamination | Oil Cleanliness Booklet

Red iron oxide, 500 x

Greasy/resinous residue, 500 x

Seal abrasion, 500 x

31

32

Oil Cleanliness Booklet | Fluid and Product Service

Fluid and Product Service

f Oil analysis particles,

water content, residual
additives
f Filter element analysis
f System ushing and
decontamination
f Advice on oil cleanliness
and oil maintenance

Products | Oil Cleanliness Booklet

Extract from the

product range

33

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Oil Cleanliness Booklet | Products

Oil Analysis Case

f Contamination control for
hydraulic uids and lubricants
f With sampling equipment

Sampling Equipment
f Safe and simple oil sampling
from pressure lines and oil
containers

Products | Oil Cleanliness Booklet

35

Laser Particle Counter

f Measurement category:
ISO 4406 oil cleanliness code
f SAE AS 4059 oil cleanliness
code
f Measurement range:
4 21 m(c) with optional
printer and pump

Datasheet: 51430

Online Particle Monitor

f Measurement category:
ISO 4406 oil cleanliness code
f 4, 6, 14 and 21 m(c)

36

Oil Cleanliness Booklet | Products

Online Water-Content
Measuring Device
f Application: Online determination of water activity in hydraulic systems and lubricating oil
f Measurement range: 0 100 %
of the saturation of water in oil
f With optional data memory,
network or alarm module

VacuClean Oil Purication

f Operating data: End vacuum
up to 50 mbar
f Oil ow rate: 20 l/min,
5 50 l/min, 5 80 l/min

Products | Oil Cleanliness Booklet

37

Ofine Filter Units

(portable, 2- and
4-wheel design)
f Volume ow: 10, 15, 30, 35,
50, 80 l/min.
f Filter type: 40 LE 0018,
7 SL 45, 7 SL 130, 40 FLE
0045, 40 FLE 0095,
40 FLE 0120
f Adjustable volume ow:
40 150 l/min.
f Filter type: 40 FLE 0270C

Wide Product Range of

Filterelements made of
paper, metal and berglass
f Filtration grade: 1 1500 m
f Filter area: 10 cm2 4,8 m2

Datasheet: 51420

38

Oil Cleanliness Booklet | Products

Inline Filter
Datasheet:
51400 Type
51401 Type
51402 Type
51403 Type
51421 Type
51422 Type
51423 Type

40/100 LEN 0040 to 0400

40 FLEN 0160 to 1000
100 FLEN 0160 to 0630
16 FE 2500 to 7500
245 LEN 0040 to 0400
350 LEN 0040 to 0400
445 LEN 0040 to 1000

Tank Mounted Filter

Datasheet:
51424 Type 10 TEN 004
51425 Type 10 TEN 0160, 0250,
0400, 0630,
1000

Products | Oil Cleanliness Booklet

39

Duplex Filter/
Change-Over Inline Filter
Datasheet:
51406 Type
51407 Type
51408 Type
51409 Type
51410 Type

50/150 LDN 0040 to 0400

40 FLDKN 0063 to 0630
40 FLDN 0160 to 1001
100 FLDN 0160 to 1000
16 FD 2500 to 7500

Manifold Mounted Filter

Datasheet:
51417 Type
51418 Type
51419 Type
51427 Type

450
245
350
320

PBFN 0040 to 1000

PSFN 0040 to 0400
PSFN 0040 to 1000
PZR 025, 075, 125

40

Oil Cleanliness Booklet | Products

Filter for
Mobile Hydraulics
Datasheet:
51426 Type 7SL 30 to 260

Filter for Process

Engineering
Type
Type
Type
Type

16
40
16
40

FKE 25/400 to 150/2500

FKE 25/400 to 150/2500
FKD 25/400 to 150/2500
FKD 25/400 to 150/2500

Design coated in Steel

and Stainless Steel

Notice | Oil Cleanliness Booklet

41

42

Oil Cleanliness Booklet | Notice

Notice | Oil Cleanliness Booklet

43

Bosch Rexroth
Filtration Systems GmbH
Hardtwaldstrae 43
68775 Ketsch
Germany
Phone +49 6202 603-0
Fax
+49 6202 603-199
info-ket@boschrexroth.de
www.boschrexroth.com/lter

The data specied above only serve to describe the

product. As our products are constantly being further
developed, no statements concerning a certain
condition or suitability for a certain application can
be derived from ourinformation. The information given
does not release the user from the obligation of own
judgment and verication. It must be remembered
that our products are subject to a natural process
of wear and aging.

RE 08016/2011
Bosch Rexroth AG 2011

Subject to revisions!
Printed in Germany